Operator's manual

SortMaster Compact (KS39)

Operator's manual

SortMaster Compact (KS39)

Original operator's manual

Edition 2022-07-01
 Order Information Please specify when ordering this document:
Operator's manual
SortMaster Compact (KS39)
Edition 2022-07-01
Document number B1172en

TRUMPF Werkzeugmaschinen SE + Co. KG

Address for orders Technische Redaktion
Johann-Maus-Straße 2
D-71254 Ditzingen
Fon: +49 7156 303 - 0
Internet: http://www.trumpf.com
E-Mail: [email protected]

© TRUMPF Werkzeugmaschinen SE + Co. KG

 Table of contents

Chapter 1 Safety

1 Safety concept 1‐3

2 Regulations and guidelines 1‐5

3 Terms 1‐6

4 Laser classes 1‐7

4.1 Overview of laser classes 1‐7

5 Operational safety 1‐8

5.1 Intended use 1‐8
5.2 Authorized personnel 1‐9

6 Hazards 1‐10
6.1 Mechanical dangers 1‐10
Dangers due to moving the beam guard 1‐10
Falling or tilting automation component 1‐10
Sharp-edged workpieces 1‐11
Unexpected movement of pneumatically 1‐11
operated components
Hazards due to transport cart 1‐12
Hazards due to moving the enclosed pro- 1‐13
tective housing
Hazards due to Y axis edge 1‐13
Hazards due to moving the lift axis 1‐13
6.2 Hazards due to laser radiation 1‐13
Hazards due to laser radiation 1‐13
6.3 Dangers from electricity 1‐14
Dangers due to the open electrical cabinet 1‐14
6.4 Thermal dangers 1‐14
Hot workpieces 1‐14
6.5 Dangers due to static magnetic fields 1‐15
Fanning magnets for sheet separation 1‐15

B1172en 2022-07-01 Table of contents 0‐1

 7 Measures to be taken by the manufacturer 1‐16
7.1 Danger zones and safeguarding device 1‐16

8 Organizational measures to be taken by 1‐19

the user
8.1 Training and instructing operators 1‐19
8.2 Due diligence when operating the system 1‐19
Water protection 1‐20
8.3 Spare parts, accessories, software, operating 1‐21
materials

9 Disassembly and disposal 1‐22

Chapter 2 Installation conditions

Who does what? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐5

2.1 Space requirements 2‐5
2.2 Floor requirements 2‐5
Surface 2‐5
Floor quality 2‐7
2.3 Weight load 2‐7
2.4 Ambient conditions 2‐8
2.5 Air purity 2‐8

3 Compressed air supply 2‐9

4 Electrics 2‐10
4.1 Power supply 2‐10
4.2 Power supply 2‐10
Uninterruptible Power Supply (UPS) 2‐10
Leakage currents 2‐10
Residual current device (RCD) 2‐11

0‐2 Table of contents 2022-07-01 B1172en

 Power supply configurations 2‐11
Protective earth conductor 2‐12
4.3 Network link 2‐13

5 Transport 2‐14
5.1 Preparing transport 2‐14
Transport dimensions 2‐14
5.2 Permitted auxiliary tools 2‐16
5.3 Checking, unloading and transporting compo- 2‐16
nents
At the time of delivery: checking compo- 2‐16
nents
Unloading and transporting automation 2‐17
components and other components

Chapter 3 Description

1 Concept 3‐2

2 The most important assemblies 3‐3

3 Safety 3‐4
3.1 Nameplate and CE marking 3‐4

4 Additional equipment, tools, materials 3‐5

5 Technical data 3‐6

B1172en 2022-07-01 Table of contents 0‐3

 Chapter 4 Operation

1 Moving axes manually 4‐2

2 Manual functions 4‐3

2.1 Using manual functions 4‐3

3 Stack formation during part removal 4‐4

Chapter 5 Setup

1 Contact tips 5‐2

Chapter 6 Maintenance

1 General guidelines 6‐3

2 Maintenance Overview 6‐5

3 Maintenance points 6‐7

3.1 Safety light barriers 6‐7
Checking safety light barriers 6‐7
Checking the light grid for proper function 6‐8
3.2 Suction cup slats 6‐10
Clean and replace vacuum cups as 6‐10
required
Pneumatic connections: checking the vac- 6‐12
uum and compressed air hoses
Checking the contact tips 6‐13
3.3 Protection devices 6‐14
Checking the enclosed protective hous- 6‐14
ing, the safety screen and the laser pro-
tective screen

0‐4 Table of contents 2022-07-01 B1172en

 Cleaning the laser protective screen or 6‐15
safety screen
Checking the enclosed protective housing 6‐17
at the side
Checking the rear enclosed protective 6‐18
housing (tool gate)
Safety laser scanner: cleaning the optics 6‐19
3.4 Z axis 6‐20
Linear guide: cleaning and lubricating the 6‐20
guide rails and guide carriage
Check the cable carrier 6‐21
Check the cable carrier 6‐22
3.5 Y-axis 6‐23
Linear guide: cleaning and lubricating the 6‐23
guide rails and guide carriage
Pressure control valve: checking the air 6‐24
pressure
Drive: checking the toothed belt 6‐25
Drive: Checking the geared motor 6‐26
Check the cable carrier 6‐27
3.6 Electrical X axis 6‐28
Linear guide: cleaning and lubricating the 6‐28
guide rails and guide carriage
Drive: checking the toothed belt 6‐29
Check the geared motor 6‐30
Check the cable carrier 6‐31
3.7 X axis additional stroke (option) 6‐32
Linear guide: cleaning and lubricating the 6‐32
guide rails and guide carriage
Check the cable carrier 6‐33
3.8 Side housing and tool gate 6‐34
Linear guide: cleaning and lubricating the 6‐34
guide rails and guide carriage
3.9 Front enclosed protective housing 6‐35
Linear guide: cleaning and lubricating the 6‐35
guide rails and guide carriage
Checking cable carrier 6‐36
3.10 Maintenance by Technical Service 6‐36
Have maintenance performed annually 6‐36

Chapter 7 Index

B1172en 2022-07-01 Table of contents 0‐5

0‐6 Table of contents 2022-07-01 B1172en
 Chapter 1

Safety

1 Safety concept 1‐3

2 Regulations and guidelines 1‐5

3 Terms 1‐6

4 Laser classes 1‐7

4.1 Overview of laser classes 1‐7

5 Operational safety 1‐8

5.1 Intended use 1‐8
5.2 Authorized personnel 1‐9

6 Hazards 1‐10
6.1 Mechanical dangers 1‐10
Dangers due to moving the beam guard 1‐10
Falling or tilting automation component 1‐10

B1172en 2022-07-01 Safety 1‐1

 Sharp-edged workpieces 1‐11
Unexpected movement of pneumatically 1‐11
operated components
Hazards due to transport cart 1‐12
Hazards due to moving the enclosed pro- 1‐13
tective housing
Hazards due to Y axis edge 1‐13
Hazards due to moving the lift axis 1‐13
6.2 Hazards due to laser radiation 1‐13
Hazards due to laser radiation 1‐13
6.3 Dangers from electricity 1‐14
Dangers due to the open electrical cabinet 1‐14
6.4 Thermal dangers 1‐14
Hot workpieces 1‐14
6.5 Dangers due to static magnetic fields 1‐15
Fanning magnets for sheet separation 1‐15

7 Measures to be taken by the manufacturer 1‐16

7.1 Danger zones and safeguarding device 1‐16

8 Organizational measures to be taken by 1‐19

the user
8.1 Training and instructing operators 1‐19
8.2 Due diligence when operating the system 1‐19
Water protection 1‐20
8.3 Spare parts, accessories, software, operating 1‐21
materials

9 Disassembly and disposal 1‐22

1‐2 Safety 2022-07-01 B1172en

 1. Safety concept

Chapter Safety The "Safety" chapter describes the safety concept of an automa-
tion system used in combination with a machine. It specifies the
guards and the manufacturer's design measures for safe opera-
tion of the automation.
It specifies the manufacturer's design measures and points out
dangers in handling the automation system.
The "Hazards" section is based on the manufacturer's risk
assessment and describes the residual risks. The user must
take measures to prevent the hazards. The measures must com-
ply with the national safety and accident prevention regulations
of the country in which the machine is operated.

Warning sign and Dangerous points on the automation system are marked with
information plates warning signs and information plates.

Warnings The operator's manual contains warnings, which warn of dan-

gers and specify measures to avoid these dangers.

Warnings have the following structure:

■ The signaling word designates the degree of a danger.
■ The danger description specifies the danger and possible
consequences if attention is not paid to the danger.
■ The measures for prevention of the danger are planned.

Example of a warning:

Risk of fatal injury due to falling load!

DANGER
Ø Observe safety regulations for the handling of heavy loads.
Ø Never walk under a suspended load.
Ø Use certified tackle and means of transportation of sufficient
size.
Ø Employ qualified technicians to transport the machine.
Ø Carry out transport in accordance with the transport regula-
tions.

A warning contains signaling words that are explained in the fol-

lowing table:

Signaling word Description

DANGER If the dangerous situation is not prevented, death or
serious injuries will result.
WARNING If the dangerous situation is not prevented, death or
serious injuries could result.

B1172en 2022-07-01 Safety concept 1‐3

 Signaling word Description
CAUTION If the dangerous situation is not prevented, light inju-
ries could result.
NOTICE If the situation is not prevented, damage to property
could result.
Signaling words Tab. 1-1

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 2. Regulations and guidelines

Laws and guidelines in the Automation components are always used in combination with a
EU machine.
TRUMPF issues an EU declaration of conformity for the
machine in accordance with EC Machinery Directive 2006/42/
EC. This EU declaration of conformity is valid for the machine
and all automation components that can be attached to this
machine.

B1172en 2022-07-01 Regulations and guidelines 1‐5

 3. Terms

Term Description
Automation Supplement a machine with machine and control components that ensure that produc-
tion processes run without intervention of an operator over a long time.
Automation component Component that automates the material flow to and from the machine.
Component A component is partly completed machinery that cannot fulfil a specific function by
itself. It is intended to be incorporated into or assembled with a machine or partly
completed machinery.
Appendix A system is a network of machines and components that work together.
User The user is the person who is responsible for the operation of the machine or system
and has the authority to issue orders to employees.
Terms Tab. 1-2

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 4. Laser classes

4.1 Overview of laser classes

Laser products are divided into laser classes as per the interna-
tional standard IEC 60825-1 (USA: ANSI Z136.1, ANSI B11.21).
The laser class corresponds to the hazard level of the laser light
emitted.

Laser class Description

1 The accessible laser radiation is not dangerous under normal, foreseeable conditions.
1M The accessible laser radiation lies in the visible spectral range of 302.5 nm to 4000 nm. The
accessible laser radiation is not dangerous for the eye as long as the cross section is not
reduced using optical instruments (magnifying glasses, lenses, telescopes).
2 The accessible laser radiation lies in the visible spectral range (400 nm to 700 nm). It is not
dangerous for the eyes when the exposure time is limited (up to 0.25 s). Additional radiation
parts outside the wavelength spectrum of 400-700 nm fulfill the conditions of class 1.
The human eye is usually protected from laser radiation by turning away and closing the lid.
2M The accessible laser radiation lies in the visible spectral range of 400 nm to 700 nm. It is
not harmful to the human eye in the case of short exposure times (up to 0.25 s) as long as
the laser beam is not observed through optical instruments (magnifying glass, lens, tele-
scope). Additional radiation parts outside the wavelength spectrum of 400-700 nm fulfill the
conditions of class 1M.
The human eye is usually protected from laser radiation by turning away and closing the lid.
3R The accessible laser radiation is in the wavelength spectrum of 302.5 nm to 106 nm and is
hazardous to the eye. The power/energy is max. 5x the limit value of the permissible class 2
laser radiation in the wavelength range from 400 nm to 700 nm.
3B The accessible laser radiation is very dangerous to the eyes and also to the skin.
Looking directly into the laser beam on class 3C lasers is dangerous. A beam bundle can be
safely seen via a diffused reflector if the following conditions are simultaneously applicable:
■ The minimum viewing distance between the screen and the cornea is 13 cm.
■ The maximum monitoring duration is 10 s.
■ There are no directed beam parts that can enter the eye.
A beam bundle can be monitored only via a diffuser if there are no directed beam parts.
The accessible laser radiation from class 3B laser products can damage the skin if the maxi-
mum permissible exposure values are exceeded.
4 The accessible laser radiation is very dangerous to the eyes and dangerous to the skin. Dif-
fused laser radiation can also be dangerous.
Safety precautions must be implemented for laser devices of class 4; adequate eye
protection is primarily important.
Laser systems of class 4 are usually sufficiently powerful to burn the skin, ignite fires and ion-
ize the atmosphere during focussing. Thus, a series of additional safety measures is required.
Overview of laser classes Tab. 1-3

B1172en 2022-07-01 Laser classes 1‐7

 5. Operational safety

The automation system can result in the following dangers if it

is used inappropriately or for purposes other than those
intended or if it is not safe to operate:
■ Dangers to the safety of the personnel.
■ Damage to the system and to other property of the operator.

5.1 Intended use

Automation The user may use the automation components only in the indus-
trial sector.
The automation component may only be used in combination
with a punching/punch laser machine from TRUMPF.
Installation, operating and transport conditions defined by
TRUMPF must be adhered to and maintenance work must be
carried out in accordance with the Operator's manual. The user
must observe the regulations of the country in which the
machine is being operated as well as national and regional
safety and accident prevention regulations.
The user may remove parts from the machine table of the
machine using the automation component and deposit them in a
sorted manner.
Standard values for the flatness of metallic materials are EN
ISO 9444-2 and EN 10051 for hot-rolled sheets and EN 10131
for cold-rolled sheets.

The following is not permitted:

■ Any working procedure that impairs the safety.
■ Using workpieces with dirty or rough surfaces, e.g. scaled,
scarred, heavily oiled, rusty or sandblasted workpieces. The
required vacuum will otherwise not be established at the suc-
tion cups of the automation component.

Disclaimer Any use going beyond this is considered to be unauthorized

use. TRUMPF is not liable for any damage, especially personal
injury and damage to property as well as production failures
resulting from this. The risk is borne solely by the user. The war-
ranty will be voided.
If the user changes or modifies the automation component, then
the user and no longer TRUMPF is responsible for the safety of
the automation component.

1‐8 Operational safety 2022-07-01 B1172en

 5.2 Authorized personnel

■ Only authorized and trained personnel must be used for

setup and maintenance work.
■ Trained specialist personnel may do the following:
− Transport the automation components to the installation
site.
− Carry out work at the pneumatic and electrical modules.
− Remove the automation components.

B1172en 2022-07-01 Operational safety 1‐9

 6. Hazards

The "Hazards" section is based on the manufacturer's risk

assessment and describes the residual risk. The user must take
measures to prevent the hazards.

6.1 Mechanical dangers

Dangers due to moving the beam guard

Object in travel range of the beam guard.

CAUTION
Risk of injury!
Ø Do not store pallets or other objects in the travel range of
the beam guard.
Ø Before moving the beam guard, remove sheets and other
objects from the support tables.

Crushing by beam guard elements.

CAUTION
Risk of injury!
Ø Do not reach between the beam guard elements.
Ø Do not reach between the beam guard elements and the
automation components.
Ø Do not reach between the beam guard elements and the
machine.

Falling or tilting automation component

The automation component must be unloaded and transported

to the installation site by the user (if not otherwise agreed on in
the contract).

1‐10 Hazards 2022-07-01 B1172en

 Risk of fatal injury due to falling or tilting automation
DANGER components!
Ø Carry out transport work in accordance with the transport
regulations.
Ø Assign qualified personnel.
Ø Observe safety regulations for the handling of heavy loads.
Ø All persons must be clear of the danger zone during
machine transport.
Ø Use certified tackle and means of transportation of sufficient
size.
Ø Only lift components at the securing points intended for this
purpose.
Ø Only transport the automation components with the trans-
port devices mounted.
Ø Remove transport devices according the to order stipulated
in the transport regulation.
Ø Observe center of gravity position.

Sharp-edged workpieces

There is a risk of injury during manual part removal.

Workpieces have sharp edges!

CAUTION
Cutting injuries of the hands.
Ø Wear protective gloves.

Unexpected movement of pneumatically

operated components

Malfunctions, mechanical defects and stuck workpieces can lead

to pneumatically operated components not reaching their
required position. In these cases, energy is stored in the compo-
nents, and is suddenly released when the jam is freed.

B1172en 2022-07-01 Hazards 1‐11

 Risk of injury due to unexpected movement of components!
WARNING
Ø Operate the manual functions for opening and closing or
moving the pneumatic component several times.
Ø If the jam cannot be released using manual functions: press
EMERGENCY STOP to switch off the compressed air.
Ø Wait until you hear the pneumatics depressurize.
Ø Do not free stuck components and workpieces with your
hands.
Ø Maintain sufficient distance.
Ø Release stuck component or stuck workpiece with a suita-
ble tool (e.g. rubber hammer, pliers).

Hazards due to transport cart

The transport cart for the SortMaster Compact could collide with
the beam guard of the basic machine if the transport cart is not
completely at the stops and thus still protruding under the beam
guard of the basic machine. In this case the transport cart could
tilt and be pushed towards the machine operator.

To avoid a collision, the following max. permissible transport cart

dimensions are to be complied with:

Machine table height Transport cart height

1020 mm 820 mm - 900 mm
1070 mm 870 mm - 970 mm
1120 mm 920 mm - 1020 mm
1200 mm 1000 mm - 1100 mm
Max. transport cart deposit height Tab. 1-4

Risk of collision between beam guard and transport cart!

CAUTION
Ø Position the transport cart outside the travel range of the
beam guard.
Ø Comply with the max. dimensions for the transport cart.

1‐12 Hazards 2022-07-01 B1172en

 Hazards due to moving the enclosed
protective housing

Risk of crushing by enclosed protective housing elements.

CAUTION
Risk of injury!
Ø Use the index bolts for the corresponding cover for mainte-
nance work.

Hazards due to Y axis edge

Bad bruising due to banging the head.

CAUTION
Risk of injury!
Ø Pay attention to the Y axis edge when approaching the
machine table, e.g. during manual loading or unloading.

Hazards due to moving the lift axis

Risk of crushing by lift axis elements.

CAUTION
Risk of injury!
Ø Lower the lift axis on to a base or the machine table during
maintenance work.
Ø Do not reach between elements of the machine and the lift
axis.
Ø Do not reach between elements of the automation compo-
nent and the lift axis.

6.2 Hazards due to laser radiation

Hazards due to laser radiation

Danger of eye injury through laser radiation.

WARNING
Ø Do not look directly into the beam.
Ø All beam guard elements must be checked on a daily basis!
Ø In the event of multi-shift operation: all beam guard ele-
ments must be checked at the start of the shift.

B1172en 2022-07-01 Hazards 1‐13

 6.3 Dangers from electricity

Work on electrical equipment and live parts is only allowed to

be carried out by trained qualified personnel.

Dangers due to the open electrical cabinet

The electrical cabinet may be opened only by an electrician.

Electrical voltage!
DANGER
Electric shock!
Ø Keep the electrical cabinet closed.
Ø Before opening the electrical cabinet: turn off the MAIN
SWITCH and secure it against being switched back on
again. Wait for the discharging time (at least 5 minutes).

Hot components!
CAUTION
Burns!
Ø Keep electrical cabinet closed.
Ø Before opening the electrical cabinet: switch off the main
switch and secure against being switched back on.
Ø Wait for the cooling phase (minimum 5 minutes).

6.4 Thermal dangers

Hot workpieces

After the laser processing, the finished workpieces are hot.

There is a risk of burns during manual removal.

Risk of burns due to hot workpieces!

WARNING
Ø Allow workpieces to cool.
Ø Wear protective gloves.
Ø Use additional equipment to remove parts.

1‐14 Hazards 2022-07-01 B1172en

 6.5 Dangers due to static magnetic fields

Fanning magnets for sheet separation

The loading station can optionally be equipped with fanning mag-

nets to separate ferromagnetic sheets.
The expanding magnets are permanent magnets that generate a
strong magnetic field. The magnetic field and the high attractive
ferromagnetic force are constant, regardless of whether the
machine is switched on or off.

Magnetic flux density The magnetic flux density is at its highest of about 180 mT (milli
tesla) at the front surfaces of the fanning magnets. The value is
about 0.7 mT at a distance of 60 cm.

Health risk and damage to property due to strong magnetic

WARNING fields of the expanding magnets!
Ø Persons with pacemakers: keep a minimum distance of 1 m.
Ø Notify personnel, visitors or external personnel of the dan-
gers for persons with a pacemaker.
Ø Do not hold any heavy ferromagnetic parts (sheets, tools) in
the hands near the fanning magnets (<1 m).
Ø Keep watches and magnetic storage media (e.g. credit
cards) away.
Ø Do not place body parts between fanning magnet and sheet
stack.

B1172en 2022-07-01 Hazards 1‐15

 7. Measures to be taken by the
manufacturer

The automation component is integrated into the safety circuit of

the basic machine. The danger zone of the entire system is pro-
tected by guards. The automation component is only allowed to
be operated with these guards.

7.1 Danger zones and safeguarding

device

1 Shielding plates 5 EMERGENCY STOP push-but- 8 Danger zone

ton (TruDisk)
2 Integrated beam guard 6 EMERGENCY STOP push-but- 9 Laser scanner safety area
ton
3 Laser warning lamp 7 Laser protective screen 10 Safety light barrier
4 Main switch
Example: danger zone and fuse protection (Machine with automation) Fig. 103124

1‐16 Measures to be taken by the manufacturer 2022-07-01 B1172en

 Safety light barrier The standard scope of delivery of the automation component
includes a dual-beam safety light barrier for securing the danger
zone. The beams of the safety light barrier run 400 mm and
900 mm above the floor.

Notes
■ In normal mode, the danger zone of the machine and the
automation component is secured with the safety light barrier.
■ An interrupted light beam triggers a feed hold during opera-
tion: all movements of the machine and of the automation
component are automatically stopped.

Safety fencing The danger zone is completely or partially secured with a safety
fencing depending on the installation. It can be accessed
through one or more safety gates.

Main switch The automation component is switched on and off using the
main switch of the machine. The main switch can be secured
against being switched on again using a lock.

The main switch has two switch settings:

Switch setting 0 The machine / automation component is

switched off and the power supply of the
machine is disconnected.
Switch setting 1 The machine / automation component is
switched on.
Tab. 1-5

EMERGENCY STOP push- EMERGENCY STOP has the following effect:

button ■ All drives are switched off electrically.
■ The hydraulic unit and the pneumatic system are switched
off.
■ All pneumatic valves for actuating the cylinders are switched
off electrically.
■ All axis motions stop.
■ The processing is interrupted:
− An active processing program is aborted and needs to
be restarted, if required.
− The machine's home position has to be approached.
− The reference points of the axes are retained.
■ The hydraulic unit, the compact dust extractor and the
lengthwise and/or transverse conveyor, respectively, are
switched off.
■ All pneumatic movements are stopped or transferred to a
danger-free state. The compressed air supply remains unaf-
fected.
■ Vacuum remains.

B1172en 2022-07-01 Measures to be taken by the manufacturer 1‐17

 Key switch for safety mode The SAFETY-MODE key switch is located on the control panel.
It can be turned to two positions. In the right switch setting, the
key must be removed and safely kept.

Left switch setting Normal mode.

Right switch setting The machine and all safety-relevant compo-
nents are shut down safely. All axis motions
are stopped and locked, the laser beam is
switched off. Parallel to production operation of
components is not possible.
Tab. 1-6

FEED HOLD A FEED HOLD leads to the following:

■ All axis motions of the machine and automation components
are stopped.
■ All axis motions of the automation component are stopped.
■ An active vacuum is maintained on the suction cups.
■ Processing in the machine continues.

Beam guard The beam guard shields the cutting head. It prevents reflected
laser radiation or secondary radiation from escaping.

1‐18 Measures to be taken by the manufacturer 2022-07-01 B1172en

 8. Organizational measures to be taken
by the user

The user must take the following measures before starting work-
ing on the machine:
■ Perform a risk assessment in accordance with national regu-
lations. To create the risk assessment the section "Dangers"
and all warnings in the operator's manual must be taken into
account.
■ Define which personnel are responsible for safety, operation,
maintenance, setting work and service.
■ Provide personal protective equipment (for example, protec-
tive gloves, safety shoes, hearing protection, safety glasses).

8.1 Training and instructing operators

The user must take the following measures before the personnel
start working on the machine:
■ Inform personnel about possible dangers and safety meas-
ures. Chapter 1 "Safety" forms the basis.
■ Personnel are obligated to read the technical documentation
of the machine. Recommendation: obtain written confirma-
tion from the personnel.
■ Instruct personnel that warnings and warning signs are to be
observed.
■ Ensure personnel wear personal protective equipment (for
example, protective gloves, safety shoes, hearing protection,
safety glasses).

8.2 Due diligence when operating the

system

The user must take the following measures:

■ Ensure that only authorized personnel work on the system.
■ Make sure that damaged or missing warning signs on the
system are replaced.
■ Ensure that the system is clean and uncluttered.
■ Ensure a sufficient fresh air supply and sufficient lighting in
the work areas.

B1172en 2022-07-01 Organizational measures to be taken by the user 1‐19

 Ensuring the perfect User:
working order ■ The user must ensure that the system is installed as per the
installation plan and installation conditions.
■ The user must ensure that only authorized personnel works
at the system.
■ The user must ensure that damaged or missing warning
signs on the system are replaced.
■ The user or the persons appointed by him/her must operate
the system when it is in perfect working order.
■ The user must ensure that the work station at the system is
kept clean and tidy by issuing appropriate instructions and
conducting inspections.
■ The user must ensure that the working areas are supplied
with sufficient fresh air.

Operator:
■ The owner must immediately report changes (including the
operating performance) occurring in the system to the user.
The system must be checked for externally visible defects
and damage at least once per shift.

Checking danger zone and The automation component is only allowed to be put into serv-
guards ice if it is integrated into the safety circuit of the basic machine.
The danger zone of the entire system must be protected by
guards. The automation component and the machine are only
allowed to be operated with guards.
Guards are not allowed to be removed or put out of operation.
The operator must always make sure that nobody is within the
danger zone before starting up the system.

Observe the shutdown The prescribed switch-off procedures must be adhered to during
procedure all work (e.g. setting and maintenance work).

Water protection

Water-pollutant substances should not enter the ground or into

water bodies.
National regulations for water protection must be observed.

Water-pollutant materials Hydraulic oil

Lubricants
Volume of water-pollutant materials
Tab. 1-7

1‐20 Organizational measures to be taken by the user 2022-07-01 B1172en

 8.3 Spare parts, accessories, software,
operating materials

Liability disclaimer TRUMPF is not liable for damage if external parts and accesso-
ries are used or if spare parts and accessories approved by
TRUMPF are not installed or replaced properly.
TRUMPF is not liable for damages resulting from the installation
or operation of software which is not approved by TRUMPF.

Using permissible operating The approved operating materials (especially lubricating and
materials as per the cleaning agents) must be used according to regulations. Accord-
regulations ing to the GHS (Globally Harmonized System of Classification,
Labelling and Packaging of Chemicals), a safety data sheet is
required for certain operating materials.
The safety data sheet is supplied with the operating material.
The data contained therein must be taken into account.

The safety data sheet can include the following data:

■ Chemical properties.
■ Physical and safety-related specifications.
■ Transport.
■ Safety measures, storage, and handling.
■ Measures for in the event of accidents or fires.
■ Specifications for toxicology and ecology.
■ Waste code with prescribed disposal method for the operat-
ing material.

Notes
■ The safety data sheet can be requested from the manufac-
turer of the respective operating material.
■ The safety data sheets e.g. for lubricants, metal powder,
cleaners or gases can be downloaded from the TRUMPF
web page: http://www.trumpf.com/s/msds.

B1172en 2022-07-01 Organizational measures to be taken by the user 1‐21

 9. Disassembly and disposal

TRUMPF recommends commissioning Technical Service or a

specialist disposal company with the dismantling and disposal of
a machine, component or system. The information below must
be passed on to the specialist company performing the disposal
work.

Preparing disassembly The following measures must be taken to avoid dangers during
disassembly:
■ Lower moving assemblies and suspended loads. Secure or
support defective moving assemblies and suspended loads.
■ Switch off the machine, component or system and wait at
least 1 hour until residual voltages have dissipated and hot
components have cooled down.
■ If available: shut off the compressed air and gas supply and
disconnect them from the customer's system.
■ Relieve the pressure in pressurized components.
■ Clean away contamination, especially dust.
■ Have the machine, component or system disconnected from
the power supply by a trained electrician.
■ Cordon off the areas in which removal and storage are tak-
ing place.

Dangers during the Hazard Necessary action

disassembly Toxic vapors due to thermal sepa- ■ Select a suitable cutting proc-
ration of painted components or ess.
composites. ■ Wear a suitable protective mask.
■ Ensure sufficient fresh air sup-
ply.
High or eccentric center of gravity ■ Secure the assembly or
of an assembly or machine. machine against tipping.
■ Put the assembly or machine
into the transport position.
■ Use transport securing devices
to prevent tipping.
Suspended load due to assem- ■ Secure or support suspended
blies that cannot be lowered. load.
Moving assemblies (unbraked) ■ Secure movable assemblies.
after separation from the power
supply system.
Unstable assemblies after loosen- ■ Secure unstable assemblies to
ing connecting parts or anchors. prevent loosening.
Release of mechanical tension by ■ Relieve components under ten-
loosening chains, ropes and other sion in a controlled manner.
components.
Residual pressure in hydraulic or ■ Release pressure from pressur-
compressed air systems caused ized assemblies in a proper
by a defective machine or compo- manner.
nent.
Dangers during the disassembly Tab. 1-8

1‐22 Disassembly and disposal 2022-07-01 B1172en

 Chapter 2

Installation conditions
Who does what? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐5

2.1 Space requirements 2‐5
2.2 Floor requirements 2‐5
Surface 2‐5
Floor quality 2‐7
2.3 Weight load 2‐7
2.4 Ambient conditions 2‐8
2.5 Air purity 2‐8

3 Compressed air supply 2‐9

4 Electrics 2‐10
4.1 Power supply 2‐10

B1172en Installation conditions - Version 3 2‐1

 4.2 Power supply 2‐10
Uninterruptible Power Supply (UPS) 2‐10
Leakage currents 2‐10
Residual current device (RCD) 2‐11
Power supply configurations 2‐11
Protective earth conductor 2‐12
4.3 Network link 2‐13

5 Transport 2‐14
5.1 Preparing transport 2‐14
Transport dimensions 2‐14
5.2 Permitted auxiliary tools 2‐16
5.3 Checking, unloading and transporting compo- 2‐16
nents
At the time of delivery: checking compo- 2‐16
nents
Unloading and transporting automation 2‐17
components and other components

2‐2 Installation conditions - Version 3 B1172en

 Who does what?

Customer All the conditions described in this chapter must be fulfilled

before the automation components are delivered.

Technical Service The automation components are put into service by Technical
Service.

The start-up includes the following:

■ Installing, aligning, levelling and securing the automation
components.
■ Connect the machine to the customer-provided media supply
(gas, water, compressed air, ...). Only the electrician con-
tracted by the user may establish the power supply.
■ Performing a functional test.
■ Instructing personnel.

B1172en Installation conditions - Version 3 2‐3

 1. Planning aid

The planning aid provides an overview of the measures to be

taken and preparations to be made.
For details, refer to the corresponding sections of these installa-
tion conditions.

Time of event prior to Planning criterion Required measures

delivery
15 weeks Personnel and training ■ Appoint a member of staff to be responsible for
preparations for the handover of the automation
components.
■ Appoint operating and service personnel and pro-
grammers.
■ Arrange training schedules for specialist personnel.
14 weeks, but no later Installation site ■ Define the system location, taking into account the
than week... space requirements according to the installation
plan.
■ Check floor requirements:
− Floor quality.
− Flatness.
■ Take the weight and dimensions of the automation
components into account.
■ Check the requirements for ambient conditions:
− Room temperature.
− Exposure to sunlight.
− Purity of the ambient air.
■ Check the transport route:
− Gateway openings.
− Doors.
− Cable rack heights.
− Room to move freely around corners etc.
12 weeks, but no later Electrical system ■ Install electrical connections at the installation site.
than calendar week ... ■ Lay the conductor cross-section and fuse protection
according to the legal requirements.
12 weeks, but no later Compressed air supply ■ Arrange for the installation of the compressed air
than calendar week ... supply at the installation site.
− Take into account connection, purity, com-
pressed air requirements.
Four weeks, but no later Transport Provide auxiliary transport equipment.
than week ...
Note: If the machine is conveyed to the customer's
site by Technical Service, the required means of trans-
portation and auxiliary transport equipment is provided
by them.
During installation and Electrical installation At the start of the installation process: have the sys-
commissioning tem connected by a professional electrician.
Planning aid Tab. 2-1

2‐4 Planning aid - Version 3 B1172en

 2. Installation site

What does the customer Please consult a structural analyst for professional support, par-
need to do? ticularly regarding the topic of floor requirements. Give the
structural analyst the "Installation site" section and the founda-
tion plan/installation layout.

2.1 Space requirements

The arrangement of the components and required space for the

installation of the system have been documented in the
TRUMPF installation plan.
If the installation deviates from the standard installation plan, a
special installation plan is required.

2.2 Floor requirements

The quality of the prepared parts can be guaranteed only when

the floor conditions meet TRUMPF requirements.

Surface

Flatness The floor on which the system stands must be flat.

Permissible flatness deviation (flatness tolerance):

■ Footprint range: max. 12 mm (1/2 in) per 10 m (33 ft).
■ Load-bearing point range (wedge mounts or air cushions):
max. 2 mm (0.08 in) per 0.5 m (1.64 ft).
The flatness tolerance can be determined for different measur-
ing point distances from the following diagram.

B1172en Installation site - Version 3 2‐5

A Flatness tolerance B Measuring point distance
Flatness tolerance depending on the measuring point distance Fig. 65278

Measuring procedure:
The straight edge is placed on the high points of the surface
and determines the depth gauge at the lowest point. For the
selected measuring point distance the depth gauge may not be
greater than the flatness tolerance.

1 Straightedge l1 Measuring point distance

2 Vanishing line of the straight- t1 Depth gauge
edge
3 Surface
Measuring procedure for determination of the depth gauge Fig. 65581

Expansion joints ■ The entire installation surface must not have any expansion
joints.
− No joint of any kind is permitted in the load-bearing point
range of the machine and within at least 1.0 m (3 ft) of it.
− In the vicinity of a plug bore hole/a load-bearing point of
an automation component, the minimum distance to the
nearest edge of the concrete floor must be 300 mm
(12 in).

2‐6 Installation site - Version 3 B1172en

 Floor quality

Note
The floor must be oil-proof.

Elastically cushioned base ■ Continuous elastic cushioning of the base plate on a subsoil
plate with a minimum sub-grade reaction modulus of ks ≥5 MN/m3
(loess loam).

Note
Calculations must be made by a structural analyst if these
requirements are not met or bearing technology is used.

When is a structural analyst A structural analyst must be consulted under the following condi-
generally required? tions:
■ The previously mentioned requirements for an elastically
embedded base plate are not met.
■ The system is to be set up on a ceiling plate/free-span base
plate.
■ The system is to be set up on fiber-reinforced concrete or
roller-compacted concrete.
■ The system is to be installed on a floor other than the one
named above.

2.3 Weight load

Additional dynamic load in Due to the machine movement during operation, the dynamic
operation loads of ±16% can occur in addition to the static load on the
support points.

Automation SortMaster Compact (basic machine TruPunch 1000)

Components Total weight Static load at the Distribution of weight

support points of
the machine
kg (lb) N
SortMaster Compact + 10200 (22487) P1: max. 43,300 Fringe area supports the main
TruPunch 1000 (medium load.
P2: max. 35,300
format)
P3: max. 26,300
SortMaster Compact + 12800 (28219) P1: max. 53,000
TruPunch 1000 (large for-
P2: max. 56,300
mat)
P3: max. 33,500
Weights and load Tab. 2-2

B1172en Installation site - Version 3 2‐7

 SortMaster Compact (basic machine TruMatic 1000)

Components Total weight Static load at the Distribution of weight

support points of
the machine
kg (lb) N
SortMaster Compact + 11000 (24250) P1: max. 47000 Fringe area supports the main
TruMatic 1000 (medium for- load.
P2: max. 39000
mat)
P3: max. 27700
SortMaster Compact + 13300 (29321) P1: max. 64000
TruMatic 1000 (large for-
P2: max. 59000
mat)
P3: max. 33600
Weights and load Tab. 2-3

2.4 Ambient conditions

Ambient conditions

Machine condition Note Ambient temperatures

Operation Default +10 °C (+50 °F) to +40 °C (+104 °F)
Temperature limit +25°C (+77°F) / 95% rel. humidity up to +40°C (+104°F) / 40%
rel. humidity
Switched off Installation site not below +5 °C (+41 °F)
Machine ambient temperatures Tab. 2-4

2.5 Air purity

SortMaster Compact Air impurities from nearby machines or systems (e.g. welding
machines, cleaning stations) can cause malfunctions. A reliable
suction grip of the sheet by the SheetMaster Compact cannot
be ensured if there is a large amount of dust on the sheet sur-
face or if it is very dirty.
Protect the SortMaster Compact from excess contamination by
taking appropriate measures (portable barriers, compact dust
extractors, etc.).

2‐8 Installation site - Version 3 B1172en

 3. Compressed air supply

Symbol in the installation

plan

Fig. 11140

Compressed air connection The compressed air connection of the SortMaster Compact is
established at the basic machine.

Connection and
consumption values
Compressed air consumption of ∅ 33 (19.42) m3/h
SortMaster Compact (volume under (cfm)
Max. 90 (53)
standard conditions) 1
Connected loads for compressed air Tab. 2-5

SortMaster Compact supply

lines
Minimum nominal diameter of the supply lines 1" (DN25) -
Recommendation for the nominal diameter of the sup- ¾" (DN20) -
ply lines (up to basic machine service unit)
Length of the connecting line max. 25 (82) m (ft)
Supply lines for compressed air supply Tab. 2-6

Compressed air properties Property Request Quality Recommendation

at the tapping point class 2
Dust-free Max. particle size: 7 Air filter on the com-
40 µm pressor
Max. particle density:
10 mg/m3
Conden- Cooled down to 4 Cold dryer
sate-free +3 °C (+37 °F) (pres-
sure dew point)
Oil-free Maximum oil content: 4 Oil-free sealing screw-
5 mg/m3 type compressor with
active carbon filter
Compressed air properties at the tapping point Tab. 2-7

1 Recommendation: Design the on-site volume flow rate 20 to 25 %

higher. Reason: For compensating pressure fluctuations during opera-
tion.
2 ISO 8573-1; 2010 edition

B1172en Compressed air supply - Version 3 2‐9

 4. Electrics

Target group The specifications in the "Electrical" section must be imple-

mented by a company which specializes in electrical installations.

IEC/NEC conditions The IEC conditions apply worldwide, the NEC conditions apply
only to Canada and the USA.

4.1 Power supply

Symbol in the installation

plan

Fig. 29327

Notes
■ The automation components are supplied by the basic
machine.

4.2 Power supply

Uninterruptible Power Supply (UPS)

The following applies in the event that it is necessary to connect

the system to an uninterruptible power supply (UPS):
■ When working out the dimensions of the UPS, the short-cir-
cuit and overload responses of the UPS system are to be
taken into account alongside the continuous power and the
electrical connected loads.
■ As a rule: overload capacity of the UPS ≥200 % for 0.5 s.

Note
The dimensioning of the uninterruptible power supply must be
established without fail by the manufacturer of the UPS plant!

Leakage currents

Leakage currents greater than 10 mA can occur at the ground

wire connection when power electronics are used and EMC pro-
tective measures are taken. A corresponding warning sign is

2‐10 Electrics - Version 3 B1172en

 present at the power connection.
Additional requirements for the electrical equipment regarding
the leakage currents on the protective earth conductor (PE)
must be taken into account by the user in accordance with
locally applicable standards/regulations.

Residual current device (RCD)

Notes
■ Whether a residual current circuit breaker has to be used
depends on the local electricity company.
■ On the line side, only residual current circuit breakers of
type B (sensitive to all types of fault current, EN
50178/5.2.11.2; VDE 0160) are approved.

A fault current circuit breaker provides protection from fault cur-

rents due to directly or indirectly touching live parts.

Residual current circuit If a fault current circuit breaker is used to provide protection
breaker for direct contact from direct contact, an isolating transformer must be used
(EN 50178 section 5.2.11.1, VDE 0160). This is because the
leakage current resulting from the design is >30 mA.

Fault current circuit breaker If a fault current circuit breaker is to be used to provide protec-
for indirect contact tion from indirect contact, this must be selected depending on
the machine's fault current.

Note
In rare cases, user-side voltage fluctuations on the machine's
power input filter may lead to higher leakage currents than the
typically specified value. The main power supply system and the
machine must then be separated by an isolating transformer.
Typical leakage currents are 300 mA.

Power supply configurations

A TN system with grounded star point is the standard power

supply configuration for the connection.
When connecting the machine to a power supply system with a
grounded line conductor, an isolating transformer must be used.

B1172en Electrics - Version 3 2‐11

 NEC conditions Power supply configuration:
■ A mains supply in star connection and with a grounded star
point (Solidly Grounded Wye) is required.
■ If the existing power supply system is in delta connection
(Corner Grounded Delta), the user must install a grounded
isolating transformer in star connection (with grounded star
point) (see NEC item 450-5).

Grounding:
■ The machine and power distributor system must be equip-
ped with a grounding cable in accordance with NEC article
250, "Grounding".
■ For details on grounding power distributor systems and
industrial plants, refer to the NEC standards or consult an
electrician or the power station.

Overvoltage protection (SPD):

■ The machine contains safety circuits. Additional require-
ments for the electrical equipment regarding overvoltage pro-
tection must be taken into account by the user in accord-
ance with locally applicable standards/regulations.

IT system

A surge diverter is required if the machine is connected to an IT

system.

TRUMPF recommends surge diverters from the following manu-

facturers:
■ Phoenix Contact GmbH & Co. KG, Flachsmarktstrasse 8,
32825 Blomberg, Germany e-mail: [email protected].
■ Dehn+Söhne, PO Box No. 1640, D-92306 Neumarkt, E-mail:
[email protected].

Protective earth conductor

External live or conductive components (e.g. units, safety fen-

ces, handrails) in the immediate vicinity of the machine (<2.5 m
distance) must be connected to the machine with a protective
earth conductor for the purpose of equipotential bonding.

2‐12 Electrics - Version 3 B1172en

 4.3 Network link

■ If a VLAN (Virtual Local Area Network) is to be set up, use

only a port-based (untagged) VLAN.
■ Secure communication via a proxy server is only possible if
no SSL Interception is carried out by the proxy. Any alterna-
tive procedure is only permissible after consultation with
TRUMPF.
■ TRUMPF recommends the following:
− Only operate TRUMPF machines in segmented networks.
− Execute processing programs within the network in a
demilitarized zone. The machine must not be allowed to
access the customer's IT network.
− Limit the communication possibilities between machines
in the OT network to what is necessary.

Electrical cabinet interface An RJ45 interface is provided in the machine electrical cabinet
for the network connection.

B1172en Electrics - Version 3 2‐13

 5. Transport

The arrangements and transport of the system from the truck to

its final installation site need to be prepared and carried out.

Machine conveyance to In some countries the user can have TRUMPF transport the sys-
customer's site by TRUMPF tem from the truck to the final installation site, the so-called "Rig-
ging". The transport route may not exceed the length contrac-
tually agreed to. The transport route must be flat, with no steps
or ramps.
If the user has commissioned TRUMPF with the rigging of the
machine, the user must only ensure that the transport route
meets the requirements mentioned below. TRUMPF will deal
with all the other points mentioned in the following, including
auxiliary tools and means of transportation.

5.1 Preparing transport

Before the automation component is delivered, check the follow-

ing:

■ Is there sufficient space for transport to the installation site?

■ Can the floor can be crossed with armored rollers, etc.?
■ Are the gateway openings, header heights and cable rack
heights sufficient?

Transport dimensions

Notes
■ The transport dimensions were calculated to include packag-
ing and pallet, and correspond to the status at the time of
delivery.
■ If the SortMaster Compact is transported together with the
basic machine, it is attached to the basic machine during
transport. The SortMaster Compact is transported as retrofit
kit independently of the basic machine.

2‐14 Transport - Version 3 B1172en

 The transport dimensions differ, depending on whether the
SortMaster Compact is transported by truck, in a container or
independently of the basic machine (retrofitting).
■ Transport by truck:
− The specified transport dimensions include the basic
machine and the SortMaster Compact.
− The SortMaster Compact is attached to the basic
machine mechanically and electrically.
− The cover is attached.
■ Transport by container:
− The specified transport dimensions include the basic
machine and the SortMaster Compact.
− The SortMaster Compact is attached to the basic
machine mechanically and electrically.
− The cover is not attached and is packed separately.
− The suction cup slat is swiveled in.
■ Retrofitting:
− The SortMaster Compact is sent independently of the
basic machine.
− The cover is not attached and is packed separately.
− The suction cup slat is swiveled in.

SortMaster Compact Length Width Height

mm (in)
Transport by truck (axis and hood installed)
SortMaster Compact on S19/K07 (MF) 5150 (203) 2950 (116) 2300 (91)
SortMaster Compact on S20/K09 (MF) 5000 (197) 2950 (116) 2410 (95)
SortMaster Compact on S19/K07 (LF) 5440 (214) 2950 (116) 2300 (91)
SortMaster Compact on S20/K09 (LF) 5440 (214) 2950 (116) 2410 (95)
Transport by container (axis installed, hood separate)
SortMaster Compact on S19/K07 (MF) 5150 (203) 2300 (91) 2300 (91)
SortMaster Compact on S20/K09 (MF) 5000 (197) 2300 (91) 2410 (95)
SortMaster Compact on S19/K07 (LF) 5440 (214) 2300 (91) 2300 (91)
SortMaster Compact on S20/K09 (LF) 5440 (214) 2300 (91) 2410 (95)
Hood (in MC box) 2200 (87) 2000 (79) 1500 (59)
Retrofitting
Axis 3220 (127) 1600 (63) 1572 (62)
Hood (in MC box) 2200 (87) 2000 (79) 1500 (59)
SortMaster Compact transport dimensions Tab. 2-8

B1172en Transport - Version 3 2‐15

 Transport weight Note
kg (lb)
SortMaster Compact 540 (1190) Transport weight of the automation component,
including packaging, beams and pallet.
Axis without transport frame 325 (716) -
Axis with transport frame 580 (1278) -
Transport weights Tab. 2-9

5.2 Permitted auxiliary tools

Notes
■ The carrying capacity of the authorized auxiliary equipment
must be selected in such a way that the maximum load can
be transported safely.

Authorized additional Crane truck for unloading the truck.

equipment
Correct size for the eyebolt supplied: Shackles and usual chains (e.g. oval suspen-
sion link)
■ Indoor crane for transporting the automation component and other components.
or
■ Forklift truck with 2 m fork extension.
A minimum of 2 hydraulic hoisting jacks, adjustable height ≤30 mm (1.2 in).
Hoisting iron (1 m (3.3 ft)) with extension.
Forklift truck for transporting accessory systems.
Notes
■ Transport SortMaster Compact using a crane and a triple-strand chain.
Chain length: 2.5 m.
Min. weight load: 1 t.
■ Transporting by lift truck is not permitted.
Tab. 2-10

5.3 Checking, unloading and

transporting components

At the time of delivery: checking

components

1. Examine all components for any transport damage.

2‐16 Transport - Version 3 B1172en

 2. Record visible damage caused during transport on the cargo
note and have the record countersigned by the truck driver.
3. Report any hidden transport damage to the insurance com-
pany and TRUMPF within six days.

Unloading and transporting automation

components and other components

Unloading and transporting The SheetMaster Compact is delivered with its own transport
SortMaster Compact regulations and may only be transported in accordance with the
transport regulations.

1. The SortMaster Compact is delivered as two separate com-

ponents:
− Hood
− Axis

Note
Transporting the SortMaster Compact with a lift truck is not
permitted.
2.
Ø Transport SortMaster Compact by crane using a triple-
strand chain.
or
Ø Transport SortMaster Compact by forklift truck with 2 m
fork extension.

B1172en Transport - Version 3 2‐17

2‐18 Transport - Version 3 B1172en
 Chapter 3

Description

1 Concept 3‐2

2 The most important assemblies 3‐3

3 Safety 3‐4
3.1 Nameplate and CE marking 3‐4

4 Additional equipment, tools, materials 3‐5

5 Technical data 3‐6

B1172en 2022-07-01 Description 3‐1

 1. Concept

Automated part removal The SortMaster Compact is an automatic unloading system for
part removal for punching and punch laser machines from
TRUMPF.
The SortMaster Compact can be used to pick up parts with a
size of 600 x 400 mm from the machine table and stack them in
a load container.

Example: TruMatic 1000 with SortMaster Compact Fig. 103136

The installation of the SortMaster Compact is neutral in terms of

space, as it is integrated into the compact machine concept of
the basic machine.
The suction cup slats have contact tips to ensure that the fin-
ished parts are separated reliably from the scrap skeleton.

Advantages ■ Automated part removal programming.

■ Process-reliable separation of finished parts by contact tips.
■ Discharge of finished parts possible via europallets and
transport carts.
■ Automated part removal reduces main operating time inter-
ruptions.

3‐2 Concept 2022-07-01 B1172en

 2. The most important assemblies

Note
The laser protective screen is only provided for a
SortMaster Compact in combination with a punch laser machine.
The safety screen is only provided for a SortMaster Compact in
combination with a punching machine.

1 Access gate 3 Tool gate 4 Safety device

2 Side cover
Fig. 103135

■ Pneumatic Z axis.
■ Electrical X axis with optional pneumatic extension axis.
■ Suction cup slats with a total of 64 individually controllable
suction points.
■ Exchangeable suction cup units with contact tips for separa-
tion detection of scrap skeletons.

B1172en 2022-07-01 The most important assemblies 3‐3

 3. Safety

3.1 Nameplate and CE marking

With the CE marking and the EU declaration of conformity and

declaration of incorporation, TRUMPF confirms that the machine
meets the basic safety and health requirements valid in the EU.
The nameplate and CE marking are on the housing.

3‐4 Safety 2022-07-01 B1172en

 4. Additional equipment, tools, materials

SortMaster Compact
Grease gun (piston ram press), mat. 1644535
Lubrication schematic, mat. no.: 2299971
Lubricating grease MICROLUBE GL 261 400 g, mat. no. 0148408
Transport cart 1210x810mm H900mm, mat. no. 2477971
Transport cart 1210x810mm H1000mm, mat. no. 2490238
Additional equipment, tools, materials Tab. 3-1

B1172en 2022-07-01 Additional equipment, tools, materials 3‐5

 5. Technical data

SortMaster Compact (KS39) TruMatic 1000 TruPunch 1000

basic machine basic
machine
Max. part size mm 600 x 400 600 x 400
Min. part size mm 70 x 30 140 x 120
Maximum part weight kg 15 15
Unloading stack height mm 150 - 250 150 - 250
Unloading area (standard) - 600 x 800 600 x 800
Unloading area (optional X axis extension) - 1200 x 800 1200 x 800
SortMaster Compact technical data Tab. 3-2

3‐6 Technical data 2022-07-01 B1172en

 Chapter 4

Operation

1 Moving axes manually 4‐2

2 Manual functions 4‐3

2.1 Using manual functions 4‐3

3 Stack formation during part removal 4‐4

B1172en 2022-07-01 Operation 4‐1

 1. Moving axes manually

The axes can be moved manually via "Setup", "Move axes",

"SortMaster Compact".

4‐2 Moving axes manually 2022-07-01 B1172en

 2. Manual functions

"Manual functions" switch machine functions and functions of

automation components. Depending on the selected main opera-
tion (Production, Setup, Maintenance or Diagnostics) different
"Manual functions" can be selected
The user interface displays the switch state of the "manual func-
tions". Example: the "Workpiece clamp" "manual function" has
the switch states "open" or "closed".

2.1 Using manual functions

1. Press Production, "Manual functions", "SortMaster Compact".

or
Ø Press Setup, "Manual functions", "SortMaster Compact".
or
Ø Press Maintenance, "Manual functions",
"SortMaster Compact".
or
Ø Press Diagnostics, "Manual functions",
"SortMaster Compact".
2. Select the selection field through the open and desired
group, e.g. "General".
Possible "Manual functions" are displayed.
3. Press the "Manual functions" for which the status is to be
modified.

B1172en 2022-07-01 Manual functions 4‐3

 3. Stack formation during part removal

To improve the stack formation quality during part removal,

observe the following notes.

Note
For more information on stack formation during part removal:
see TruTops Boost software documentation.

Suction before separation

Suction before separation Fig. 104043

To prevent any twisting of the parts during separation 3:

■ Fasten the punched part removal by suction before the part

is completely removed from the sheet.
■ In doing so, do not damage the obstruction of the punching
head (1).

3 Last processing step for completely separating the part from the sheet.

4‐4 Stack formation during part removal 2022-07-01 B1172en

Increasing the stack interval

1 Set stack interval

Setting the stack interval Fig. 104044

Increase the default stack interval (1) from 10 mm to at least

20 mm to prevent any overlapping of the stacks when removing
the punching parts.
Adjust the stack interval in TruTops Boost at "Palletization",
"Automatic configuration", "Parameters".

Processing of outer Note

contours
Only possible in combination with a punch laser machine.

1 Outer contour
Processing the outer contour Fig. 104046

If possible, process outer contours with the laser to reduce any

twisting of the part during stack formation.
Laser processing creates more clearance for part removal out-
side the obstruction (1).

B1172en 2022-07-01 Stack formation during part removal 4‐5

 Using several suction cup
units

Suction cup units Fig. 104047

Use at least three suction cup units to pick up parts for removal.
The attachment by suction with at least 3 suction cup units
results in even distribution of the suction cups on the part. The
risk of tilting or twisting of the part is reduced when the suction
cups are detached.
Use two identical suction cup units if no more than two suction
cup units can be used.

Creating small stacks Only create small stacks of small parts (e.g. size 70 mm x
40 mm), parts with extrusions and parts with angles. With bigger
stacks, the parts could slip and the stacks could tilt.
Alternative: collect parts in boxes.

Damping material on pallet Small parts and lightweight parts might spring back when they
base hit the pallet base.
Supports made of damping material can reduce the rebound of
the parts.
Alternative: collect parts in boxes.

Reduction of lubricant If there is a large amount of lubricant on the parts to be

removed (e.g from tapping), that will result in the parts sliding in
the stack.
If lubrication cannot be reduced, reduce the maximum stack
height.

4‐6 Stack formation during part removal 2022-07-01 B1172en

 Chapter 5

Setup

1 Contact tips 5‐2

B1172en 2022-07-01 Setup 5‐1

 1. Contact tips

Note
For the removal of parts with high quality requirements, espe-
cially for scratch-free removal, the contact tips of the suction
cup slats must be unscrewed.

5‐2 Contact tips 2022-07-01 B1172en

 Chapter 6

Maintenance

1 General guidelines 6‐3

2 Maintenance Overview 6‐5

3 Maintenance points 6‐7

3.1 Safety light barriers 6‐7
Checking safety light barriers 6‐7
Checking the light grid for proper function 6‐8
3.2 Suction cup slats 6‐10
Clean and replace vacuum cups as 6‐10
required
Pneumatic connections: checking the vac- 6‐12
uum and compressed air hoses
Checking the contact tips 6‐13
3.3 Protection devices 6‐14
Checking the enclosed protective hous- 6‐14
ing, the safety screen and the laser pro-
tective screen

B1172en 2022-07-01 Maintenance 6‐1

 Cleaning the laser protective screen or 6‐15
safety screen
Checking the enclosed protective housing 6‐17
at the side
Checking the rear enclosed protective 6‐18
housing (tool gate)
Safety laser scanner: cleaning the optics 6‐19
3.4 Z axis 6‐20
Linear guide: cleaning and lubricating the 6‐20
guide rails and guide carriage
Check the cable carrier 6‐21
Check the cable carrier 6‐22
3.5 Y-axis 6‐23
Linear guide: cleaning and lubricating the 6‐23
guide rails and guide carriage
Pressure control valve: checking the air 6‐24
pressure
Drive: checking the toothed belt 6‐25
Drive: Checking the geared motor 6‐26
Check the cable carrier 6‐27
3.6 Electrical X axis 6‐28
Linear guide: cleaning and lubricating the 6‐28
guide rails and guide carriage
Drive: checking the toothed belt 6‐29
Check the geared motor 6‐30
Check the cable carrier 6‐31
3.7 X axis additional stroke (option) 6‐32
Linear guide: cleaning and lubricating the 6‐32
guide rails and guide carriage
Check the cable carrier 6‐33
3.8 Side housing and tool gate 6‐34
Linear guide: cleaning and lubricating the 6‐34
guide rails and guide carriage
3.9 Front enclosed protective housing 6‐35
Linear guide: cleaning and lubricating the 6‐35
guide rails and guide carriage
Checking cable carrier 6‐36
3.10 Maintenance by Technical Service 6‐36
Have maintenance performed annually 6‐36

6‐2 Maintenance 2022-07-01 B1172en

 1. General guidelines

Proper maintenance is essential for retaining the quality of the

machine as it prevents operational malfunctions and associated
consequences.

Risk of injury during maintenance work with the machine

DANGER switched on!
Ø For example, indicate current maintenance work with a
warning sign on the operating panel or appoint a supervisor.
Ø Make sure nobody is within the danger zone before starting
up the machine.

Maintenance personnel The user must authorize the maintenance personnel to perform
maintenance work on the machine.

Depending upon the labeling, the maintenance work must be

done by the persons as specified in the following table:

Symbol Maintenance personnel

Machine operator

Trained maintenance personnel:

■ Work on the following assemblies requires specialist knowledge in the relevant area:
− Electrics.
− Hydraulics.
− Pneumatics.
− Mechanics.
− Laser.
■ National regulations also apply.
Technical Service:
This maintenance work may only be carried out by TRUMPF's Technical Service.
Maintenance personnel identification Tab. 6-1

Before putting the machine The machine must be lubricated carefully in accordance with the
into service lubrication chart before being put into service. The entire lubrica-
tion of the machine has to be checked if the machine has not
been used for a long time (e.g. sea transport). The resinous oil
must be completely removed from all lubrication points and sup-
ply lines.

Notes on cleaning ■ The entire system should be cleaned at regular intervals.

■ Brush off large elements of dirt and dust or remove them
using an industrial vacuum cleaner.

B1172en 2022-07-01 General guidelines 6‐3

 Notes on lubrication Refer to the lubrication schematic and maintenance instructions
for the lubrication of the machine. The following points should
also be observed:
■ Do not leave filler and drainage caps open for longer than
necessary and keep them clean.
■ Pump out waste oil only at operating temperature.
■ Use only lint-free cleaning cloths and low-viscosity spindle
oil ("scavenge oil") to clean oil chambers and lubricating
points. Do not use cleaning wool, kerosene or benzene.
■ Do not mix synthetic lubricating oils with mineral oils or syn-
thetic oils from other manufacturers, even if the synthetic oil
in question has equivalent properties.
■ Dispose of waste oil appropriately.

Notes on oil and water Do not use oil pumps to change water. Do not use water pumps
pumps to change oil. Alternately used pumps lead to impurity and dam-
age to the cooling water circuit.

Qualifications of All maintenance work may only be performed by persons who

maintenance personnel have been trained for the maintenance work described and who
have acquired the relevant knowledge.
Certain types of maintenance work (e.g. in the area of the RF
generators) require, in addition to the above-mentioned qualifica-
tions, complete professional training or advanced training in elec-
trotechnology.
Furthermore these specialists require authorization to perform
electrical work on this system (electrician for defined tasks in
accordance with DGUV Vorschrift 3 (former number: BGV A3)).
The regulations of the relevant country are also applicable.

6‐4 General guidelines 2022-07-01 B1172en

 2. Maintenance Overview

Interval/ operating Maintenance Maintenance point See

hours personnel
Ø Maintenance work
Daily Safety light barriers 6‐7
Ø Checking safety light barriers
Daily Safety light barriers 6‐8
Ø Checking the light grid for proper function
Daily Suction cup slats 6‐10
Ø Clean and replace vacuum cups as required
Daily Suction cup slats 6‐13
Ø Checking the contact tips
Daily Protection devices 6‐14
Ø Checking the enclosed protective housing, the safety
screen and the laser protective screen
Daily Protection devices 6‐17
Ø Checking the enclosed protective housing at the side
Daily Protection devices 6‐18
Ø Checking the rear enclosed protective housing (tool gate)
Weekly Protection devices 6‐19
Ø Safety laser scanner: cleaning the optics
Monthly Y-axis 6‐24
Ø Pressure control valve: checking the air pressure
Monthly Side housing and tool gate 6‐34
Ø Linear guide: cleaning and lubricating the guide rails and
guide carriage
Monthly Front enclosed protective housing 6‐35
Ø Linear guide: cleaning and lubricating the guide rails and
guide carriage
Every 3 months Suction cup slats 6‐12
Ø Pneumatic connections: checking the vacuum and com-
pressed air hoses
Every 6 months Z axis 6‐20
Ø Linear guide: cleaning and lubricating the guide rails and
guide carriage
Every 6 months Z axis 6‐21
Ø Check the cable carrier
Every 6 months Z axis 6‐22
Ø Check the cable carrier
Every 6 months Y-axis 6‐23
Ø Linear guide: cleaning and lubricating the guide rails and
guide carriage
Every 6 months Y-axis 6‐25
Ø Drive: checking the toothed belt

B1172en 2022-07-01 Maintenance Overview 6‐5

Interval/ operating Maintenance Maintenance point See
hours personnel
Ø Maintenance work
Every 6 months Y-axis 6‐26
Ø Drive: Checking the geared motor
Every 6 months Y-axis 6‐27
Ø Check the cable carrier
Every 6 months Electrical X axis 6‐28
Ø Linear guide: cleaning and lubricating the guide rails and
guide carriage
Every 6 months Electrical X axis 6‐29
Ø Drive: checking the toothed belt
Every 6 months Electrical X axis 6‐30
Ø Check the geared motor
Every 6 months Electrical X axis 6‐31
Ø Check the cable carrier
Every 6 months X axis additional stroke (option) 6‐32
Ø Linear guide: cleaning and lubricating the guide rails and
guide carriage
Every 6 months X axis additional stroke (option) 6‐33
Ø Check the cable carrier
Every 6 months Front enclosed protective housing 6‐36
Ø Checking cable carrier
Annually Maintenance by Technical Service 6‐36
Ø Have maintenance performed annually
As needed Protection devices 6‐15
Ø Cleaning the laser protective screen or safety screen

6‐6 Maintenance Overview 2022-07-01 B1172en

 3. Maintenance points

3.1 Safety light barriers

Checking safety light barriers

Maintenance interval: Daily

Condition
■ The machine is switched on.

1 Shielding plates 5 EMERGENCY STOP push-but- 8 Danger zone

ton (TruDisk)
2 Integrated beam guard 6 EMERGENCY STOP push-but- 9 Laser scanner safety area
ton
3 Laser warning lamp 7 Laser protective screen 10 Safety light barrier
4 Main switch
Example: danger zone and fuse protection (Machine with automation) Fig. 103124

B1172en 2022-07-01 Maintenance points 6‐7

 1. Check the safety light barriers for proper function.
2. If there is damage:
− Do not put the machine or automation components into
operation.
− Inform Technical Service.

Checking the light grid for proper function

Maintenance interval: Daily

Danger that the optoelectronic safety device will lose its

DANGER effectiveness after modifications!
Persons and body parts requiring protection will not be
detected on non-compliance.
Ø Maintenance work and alignment work, fault diagnosis or
changes made to the integration in the machine may only
be performed by personnel who are qualified for this work.

Risk of injury from the machine starting unexpectedly!

DANGER
Interference sources such as obstacles, air contaminants
or scattering media can inadvertently trigger optoelectronic
safety devices. The unnoticed removal of an interference
source can lead to the machine starting unexpectedly.
Ø Eliminate all interference sources, which may impair the
function of the optoelectronic safety device.
Ø Ensure that no one is in the danger zone during the test.

Danger of an inoperative light grid!

DANGER
Persons and body parts requiring protection will not be
detected on non-compliance.
Ø Only use the supplied test rod.
The diameter of the test rod is specified on the nameplate
of the light grid.
Ø Do not use test rods with a similar or identical diameter that
belong to other light grids.

1. Ensure that the light grid components and the connectors

are tightly assembled and free from obvious damage or mod-
ifications.
2. Ensure that no modifications have been made to access or
entry options.

6‐8 Maintenance points 2022-07-01 B1172en

 3. Ensure that the LED is lit up in green on the receiver.

Daily test of the protective device: step 1 Fig. 72726

4. Guide the test rod slowly through the protected field (see
arrow) and check whether the LED on the receiver lights up
in red.

B1172en 2022-07-01 Maintenance points 6‐9

 Daily test of the protective device: step 2 Fig. 72727
5. Guide the test rod slowly along the edges of the protected
field (see arrow) and check whether the LED on the receiver
lights up in red.
6. If required: request Technical Service.

3.2 Suction cup slats

Clean and replace vacuum cups as

required

Maintenance interval: Daily

Condition
■ The front enclosed protective housing is open.
■ The axes are in the home position.

Means, Tools, Materials

■ Clean, soft cloth.
■ Use warm water with standard, household dish detergent as
a cleaning agent.
■ Protective gloves.

6‐10 Maintenance points 2022-07-01 B1172en

 Notes
■ The vacuum cups could become soiled more quickly due to
the evaporation of foiled sheets. In this case, the vacuum
cups must be cleaned several times a day.
■ The main switch on the electrical cabinet can remain
switched on.

Risk of injury due to contact tips in the vacuum cups.

CAUTION
Ø Carry out work on the vacuum cups carefully and only with
protective gloves.

1 Vacuum cups
Suction cup slat Fig. 96589

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Move the SortMaster Compact by hand towards the control
panel.
3. Clean the vacuum cups (1) with a clean cloth and a suitable
cleaning agent.
4. Check vacuum cups for damage and replace, if necessary.
5. To replace a vacuum cup:
− Pull the suction cup off the fitting.
− Push a new suction cup on to the fitting up to the stop.

B1172en 2022-07-01 Maintenance points 6‐11

 Pneumatic connections: checking the
vacuum and compressed air hoses

Maintenance interval: Every 3 months

Condition
■ The front enclosed protective housing is open.

1 Vacuum and compressed air hoses

Pneumatic connections Fig. 96588

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Move the SortMaster Compact by hand towards the control
panel.
3. Check that the vacuum and compressed air hoses (1) are fit-
ted tightly and not damaged.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

6‐12 Maintenance points 2022-07-01 B1172en

 Checking the contact tips

Maintenance interval: Daily

Condition
■ The front enclosed protective housing is open.

Means, Tools, Materials

■ Suitable protective gloves.
■ A tool, e.g. a pin or a small sheet.

Risk of injury due to contact tips in the vacuum cups.

CAUTION
Ø Carry out work on the vacuum cups carefully and only with
protective gloves.

1 Contact tips
Suction cup slat Fig. 96587

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Move the SortMaster Compact by hand towards the control
panel.

Note
To avoid injuries, check contact tips with a suitable tool, e.g.
a pin.
3. Check contact tips (1) for completeness, damage and ease
of movement.
4. Check that the contact tips are in correct working order

B1172en 2022-07-01 Maintenance points 6‐13

 Ø Press in the contact tips using a pin, a small sheet or
similar.
or
Ø The contact tip must spring back to its initial position on
its own.

3.3 Protection devices

Checking the enclosed protective housing,

the safety screen and the laser protective
screen

Maintenance interval: Daily

Conditions
■ The front enclosed protective housing is closed.
■ Move carriage or pallet to the side, if present.

Notes
■ The main switch on the electrical cabinet can remain
switched on.
■ The laser protective screen is only provided for a
SortMaster Compact in combination with a punch laser
machine.
The safety screen is only provided for a
SortMaster Compact in combination with a punching
machine.

6‐14 Maintenance points 2022-07-01 B1172en

1 Enclosed protective housing 2 Laser protective screen
Front housing Fig. 96592

1. Turn the SAFETY-MODE key switch to the right and remove

the key.
2. Check the front enclosed protective housing (1) for damage,
deformation, holes and missing parts.
3. Check the laser protective screen from the inside and out-
side (2) for damage (e.g. discoloration, blisters, deformation,
burns).
4. If there is damage:
− Do not put the basic machine and automation compo-
nents into operation.
− Inform Technical Service.

Cleaning the laser protective screen or

safety screen

Maintenance interval: As needed

The following cleaning agents are recommended for cleaning

the laser protective screens or safety screen:
■ Anti-static plastic cleaner UBA 0197 0057, Burnus GmbH,
mat. no. 1672922
■ Intensive plastic cleaner UBA 0197 0062, Burnus GmbH,
mat. no. 1672919

B1172en 2022-07-01 Maintenance points 6‐15

 Condition
■ The front enclosed protective housing is closed.

Means, Tools, Materials

■ Clean, soft cloth.
■ Suitable cleaning agent.

Notes
■ The main switch on the electrical cabinet can remain
switched on.
■ The laser protective screen is only provided for a
SortMaster Compact in combination with a punch laser
machine.
The SortMaster Compact in combination with a punching
machine is equipped with a safety screen.

Destruction of the laser protective screen by unsuitable

NOTICE cleaning agents!
Ø Do not clean the laser protective screen with glass cleaner.
Ø Use only cleaning agents which are suitable for polycarbon-
ate.

1 Enclosed protective housing 2 Laser protective screen

Front housing Fig. 96592

1. Turn the SAFETY-MODE key switch to the right and remove

the key.
2. Clean the laser protective screen (2) with a suitable cloth
and a suitable cleaning agent.

6‐16 Maintenance points 2022-07-01 B1172en

 Checking the enclosed protective housing
at the side

Maintenance interval: Daily

Condition
■ The enclosed protective housing is closed.

Note
The main switch on the electrical cabinet can remain switched
on.

1 Enclosed protective housing 2 Laser protective screen

Front housing Fig. 96592

1. Turn the SAFETY-MODE key switch to the right and remove

the key.
2. Check the side cover for damage, deformation and missing
parts.
3. If there is damage:
− Do not put the basic machine and automation compo-
nents into operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐17

 Checking the rear enclosed protective
housing (tool gate)

Maintenance interval: Daily

Condition
■ The enclosed protective housing at the side is closed.

Note
The main switch on the electrical cabinet can remain switched
on.

1 Tool gate 2 Protective plates

Tool gate access Fig. 96590

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.

6‐18 Maintenance points 2022-07-01 B1172en

 2. Check the tool gate (1) for damage, deformation and miss-
ing parts.
3. Check that the hoses (front and rear) are fitted tightly.
4. If there is damage:
− Do not put the basic machine and automation compo-
nents into operation.
− Inform Technical Service.

Safety laser scanner: cleaning the optics

Maintenance interval: Weekly

Means, Tools, Materials

■ Soft, clean cloth and brush.
■ Cleaning agent: water.

Notes
■ Static charge will cause dust to stick to the optics. This
static charge can be reduced by an antistatic plastic cleaner
and a lens cloth from Sick.
■ Do not use abrasive cleaning agents.
■ The main switch on the electrical cabinet can remain
switched on.

Inadvertent triggering of the safety laser scanner!

NOTICE
Ø Vapors, smoke, dust and all visible particles in the air can
inadvertently trigger the machine.

1 Safety laser scanner

Safety laser scanner Fig. 103137

B1172en 2022-07-01 Maintenance points 6‐19

 1. Press EMERGENCY STOP, turn the SAFETY-MODE key
switch to the right and pull out the key.
2. On the safety laser scanner (1), remove the dust from the
optics with a soft, clean brush.
− Wipe the optics with a clean, moist cloth.

3.4 Z axis

Linear guide: cleaning and lubricating the

guide rails and guide carriage

Maintenance interval: Every 6 months

Condition
■ The axes are in the home position.

Means, Tools, Materials

■ Clean, soft cloth.
■ Lubricating grease MICROLUBE GL 261 400 g, mat. no.
0148408
■ Grease gun (piston ram press), mat. 1644535
■ Lubrication schematic, mat. no.: 2299971

1 grease nipples 2 Guide rails

Y axis: linear guide Fig. 96617

6‐20 Maintenance points 2022-07-01 B1172en

 1. Press Maintenance, "SortMaster Compact", "Service posi-
tion".
"Reached" is displayed.
2. Press Setup, "Manual functions", "Z: dropping height".
The Z axis is lowered.
3. Open the front housing.
4. Press EMERGENCY STOP, turn the SAFETY-MODE key
switch to the right and pull out the key.
5. Clean guide rails (2) with a suitable cloth.
6. Lubricate the grease nipple (1) with lubricant (1 stroke).

Check the cable carrier

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Cable carrier
Z axis: cable carrier Fig. 96622

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check individual links and fasteners of the cable carrier (1)
for damage and missing parts.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐21

 Check the cable carrier

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Cable carrier
Z axis cylinder: cable carrier Fig. 96623

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check individual links and fastenings of the cable carrier (1)
for damage and broken spots.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

6‐22 Maintenance points 2022-07-01 B1172en

 3.5 Y-axis

Linear guide: cleaning and lubricating the

guide rails and guide carriage

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

Means, Tools, Materials

■ Clean, soft cloth.
■ Lubricating grease MICROLUBE GL 261 400 g, mat. no.
0148408
■ Grease gun (piston ram press), mat. 1644535
■ Lubrication schematic, mat. no.: 2299971

1 grease nipples 2 Guide rails

Y axis: linear guide Fig. 96617

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Clean guide rails (2) with a suitable cloth.
4. Lubricate the grease nipple (1) with lubricant (1 stroke).

B1172en 2022-07-01 Maintenance points 6‐23

 Pressure control valve: checking the air
pressure

Maintenance interval: Monthly

Condition
■ The front enclosed protective housing is open.

Means, Tools, Materials

■ Pneumatic schematic of SortMaster Compact (KS39).

Notes
■ Set the pressure according to the specifications in the pneu-
matic schematic.
■ To set pressure as accurately as possible, use system pres-
sure displayed in HMI. Setting the pressure according to the
pressure gauge is not sufficient.

1 Pressure control valve

Y axis: pressure control valve Fig. 96591

Check the pressure 1. Check the SortMaster Compact system pressure displayed
in HMI.
− Set value and permissible tolerance: See
SortMaster Compact pneumatic schematic.
2. System pressure within permissible tolerances: No further
measures required.
or
Ø System pressure outside the permissible tolerance:
Adjust the pressure at the pressure control valve.

6‐24 Maintenance points 2022-07-01 B1172en

 Setting the pressure 3. Read the SortMaster Compact system pressure on the HMI.
− Calculate the difference: Difference = Set value - Display
value (HMI).
− Readjust the pressure at the pressure control valve
according to the calculated difference.
− Check the system pressure on HMI again, repeat setting
procedure if necessary.

Drive: checking the toothed belt

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1. Move the SortMaster Compact away from the control panel

by hand, until the toothed belt is clearly visible.
2. Check the toothed belt for abrasion, wear and tension.
3. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐25

 Drive: Checking the geared motor

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Geared motor
Y axis: drive Fig. 96619

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check the geared motor (1) for oil leaks and damage.
4. If there is damage:
− Do not put the machine into operation.
− Inform Technical Service.

6‐26 Maintenance points 2022-07-01 B1172en

 Check the cable carrier

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Cable carrier
Y axis: cable carrier Fig. 96620

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check individual links and fastenings of the cable carrier (1)
for damage and broken spots.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐27

 3.6 Electrical X axis

Linear guide: cleaning and lubricating the

guide rails and guide carriage

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

Means, Tools, Materials

■ Clean, soft cloth.
■ Lubricating grease MICROLUBE GL 261 400 g, mat. no.
0148408
■ Grease gun (piston ram press), mat. 1644535
■ Lubrication schematic, mat. no.: 2299971

1 Guide rails and guide carriage

Electrical X axis: linear guide Fig. 96583

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Clean guide rails and guide carriage with a suitable cloth.
4. Lubricate the guide rails and guide carriage with lubricant
(1 stroke).

6‐28 Maintenance points 2022-07-01 B1172en

 Drive: checking the toothed belt

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Toothed belt
Electrical X axis: drive Fig. 96614

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Move the SortMaster Compact by hand into a position in
which the toothed belt is visible.
3. Check the toothed belt (1) for abrasion, wear, damage and
cracks.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐29

 Check the geared motor

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Geared motor
Electrical X axis: geared motor Fig. 96615

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check the geared motor (1) for oil leaks and damage.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

6‐30 Maintenance points 2022-07-01 B1172en

 Check the cable carrier

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Cable carrier
Electrical X axis: cable carrier Fig. 96616

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check individual links and fastenings of the cable carrier (1)
for damage and broken spots.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐31

 3.7 X axis additional stroke (option)

Linear guide: cleaning and lubricating the

guide rails and guide carriage

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

Means, Tools, Materials

■ Clean, soft cloth.
■ Lubricating grease MICROLUBE GL 261 400 g, mat. no.
0148408
■ Grease gun (piston ram press), mat. 1644535
■ Lubrication schematic, mat. no.: 2299971

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Clean guide rails and guide carriage with a suitable cloth.

6‐32 Maintenance points 2022-07-01 B1172en

 Check the cable carrier

Maintenance interval: Every 6 months

Condition
■ The front housing is open.

1 Cable carrier
Pneumatic X axis: cable carrier Fig. 96618

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Check individual links and fastenings of the cable carrier (1)
for damage and broken spots.
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

B1172en 2022-07-01 Maintenance points 6‐33

 3.8 Side housing and tool gate

Linear guide: cleaning and lubricating the

guide rails and guide carriage

Maintenance interval: Monthly

Condition
■ The front housing is open.

Means, Tools, Materials

■ Clean, soft cloth.
■ Lubricating grease MICROLUBE GL 261 400 g, mat. no.
0148408
■ Grease gun (piston ram press), mat. 1644535
■ Lubrication schematic, mat. no.: 2299971

1 Left guide rail cover 2 Guide rail tool gate

Tool access cover: linear guide Fig. 96584

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Put the SortMaster Compact into a suitable position by hand.
3. Clean guide rails and guide carriage (1) with a suitable cloth.
4. Lubricate the guide rails and guide carriage with lubricant
(1 stroke).

6‐34 Maintenance points 2022-07-01 B1172en

 3.9 Front enclosed protective housing

Linear guide: cleaning and lubricating the

guide rails and guide carriage

Maintenance interval: Monthly

Condition
■ Front hood is open.

Means, Tools, Materials

■ Clean, soft cloth.
■ Lubricating grease MICROLUBE GL 261 400 g, mat. no.
0148408
■ Grease gun (piston ram press), mat. 1644535
■ Lubrication schematic, mat. no.: 2299971
■ Suitable climbing aid, such as a stepladder.

2 Side enclosed protective housing: guide rails and 3 Rear enclosed protective housing (tool gate): guide
guide carriage rails and guide carriage
Fig. 96584

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Move the SortMaster Compact by hand towards the control
panel.
3. Clean guide rails and guide carriages (2) and (3)with a suita-
ble cloth.
4. Lubricate the guide rails and guide carriage with lubricant (1
stroke).

B1172en 2022-07-01 Maintenance points 6‐35

 Checking cable carrier

Maintenance interval: Every 6 months

Condition
■ The front enclosed protective housing is open.

1. Press EMERGENCY STOP, turn the SAFETY-MODE key

switch to the right and pull out the key.
2. Move the SortMaster Compact by hand towards the control
panel.
3. Check individual links and fasteners for wear (damage, bro-
ken spots).
4. If there is damage:
− Do not put the machine and SortMaster Compact into
operation.
− Inform Technical Service.

3.10 Maintenance by Technical Service

Have maintenance performed annually

Maintenance interval: Annually

Maintenance point Maintenance work

Suction cup slats Check the alignment/adjustment of suction cup slats.
Bulkhead Compressed air inlet ports: Check pneumatic hose.
Instrument plate Compressed air inlet ports: Check vacuum and pneumatic hoses.
Z axis Compressed air inlet ports: Check cylinders, unlockable non-return valves
and hoses for tightness.
Z axis Compressed air inlet ports: Check pneumatic hoses for wear.
Y axis Drive: Re-tension the toothed belt.
Electrical X axis Compressed air inlet ports: Check pneumatic hoses for wear.
Tab. 6-2

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐36 Maintenance points 2022-07-01 B1172en

Index

A I
Additional equipment, tools, materials ......3‐5 Information plates ......................................1‐3
Air purity .................................................... 2‐8 Intended use ..............................................1‐8
Ambient conditions .................................... 2‐8 Isolating transformer ................................2‐11
Auxiliary tools .......................................... 2‐16 IT system .................................................2‐12

C L
Cable carrier .................................... 6‐6, 6‐36 Laser classes ............................................ 1‐7
CE marking ................................................3‐4 Laser protective screen ..6‐5, 6‐6, 6‐14, 6‐15
Compressed air Liability disclaimer ................................... 1‐21
Properties .............................................. 2‐9 LoadMaster ................................................2‐9
Compressed air hose ...................... 6‐5, 6‐12
Compressed air supply ............................. 2‐9
Connection and consumption values ... 2‐9
Contact tips ...................... 3‐2, 5‐2, 6‐5, 6‐13 M
Main operating time interruption ...............3‐2
Main switch ..............................................1‐17
D Maintenance by Technical Service . 6‐6, 6‐36
Maintenance personnel ............................. 6‐3
Danger zone
Safeguarding device ........................... 1‐16

N
E Network link .............................................2‐13

Electrics ................................................... 2‐10

EMERGENCY STOP push-button .......... 1‐17
Enclosed protective housing ........... 6‐5, 6‐14 O
At the side ................................... 6‐5, 6‐17
EU declaration of conformity .................... 3‐4 Optics ............................................... 6‐5, 6‐19
EU declaration of incorporation ................ 3‐4
Expansion joints ........................................ 2‐6
P
Part removal .............................................. 3‐2
F Planning aid ...............................................2‐4
FEED HOLD ............................................1‐18 Pneumatic connection ..................... 6‐5, 6‐12
Floor quality ...............................................2‐7 Power supply ...........................................2‐10
Floor requirements .................................... 2‐5 IT system .............................................2‐12
Protection devices ....................6‐5, 6‐6, 6‐14

B1172en 2022-07-01 Index 7‐1

R
Requirements, space ................................ 2‐5

S
Safety fencing ..........................................1‐17
Safety laser scanner ....................... 6‐5, 6‐19
Safety light barrier ...................................1‐17
Safety light barriers ........................... 6‐5, 6‐7
Safety screen ................. 6‐5, 6‐6, 6‐14, 6‐15
SheetMaster
Supply lines ...........................................2‐9
Suction cup slats ............................. 6‐5, 6‐10

T
Technical data ........................................... 3‐6
Tool gate .......................................... 6‐5, 6‐18
Transport ..................................................2‐14
Auxiliary tools ...................................... 2‐16
Transport cart ............................................ 3‐2

U
UPS ......................................................... 2‐10

V
Vacuum cup ..................................... 6‐5, 6‐10
Vacuum hose ................................... 6‐5, 6‐12

W
Warning signs ............................................1‐3
Warnings ....................................................1‐3
Water protection ...................................... 1‐20
Weight load ............................................... 2‐7

7‐2 Index 2022-07-01 B1172en